Rubber composition, and pneumatic tire

Abstract

Provided are a rubber composition achieving balanced improvement in processability, fuel economy, rubber strength, abrasion resistance, wet-grip performance, and handling stability, and a pneumatic tire including the composition. The rubber composition includes, per 100% by mass of a rubber component, at least 35% by mass of SR, the composition including a conjugated diene polymer and a silica having N 2 SA of 40-400 m 2 /g, the polymer being obtained by polymerizing a monomer component including a conjugated diene compound and a silicon-containing vinyl compound using a polymerization initiator of formula (I): to produce a copolymer, and reacting a compound containing nitrogen and/or silicon atoms with an active terminal of the copolymer, wherein the amount of the diene polymer is 1-90% by mass and the amount of polyisoprene-based rubber is 0-40% by mass, each per 100% by mass of the rubber component, and the amount of the silica is 10-150 parts by mass per 100 parts by mass of the rubber component.

The invention claimed is: 
     
       1. A rubber composition, comprising, based on 100% by mass of a rubber component, not less than 35% by mass of styrene-butadiene rubber, the rubber composition comprising
 a conjugated diene polymer, and 
 a silica having a nitrogen adsorption specific surface area of 40 to 400 m 2 /g, 
 the conjugated diene polymer being obtained by polymerizing a monomer component including a conjugated diene compound and a silicon-containing vinyl compound in the presence of a polymerization initiator represented by the following formula (I): 
 
       
         
           
           
               
               
           
         
         wherein i represents 0 or 1; R 11  represents a C 7-80  hydrocarbylene group; R 12  and R 13  each are a hydrocarbyl group, or R12 and R13 are joined together to form a hydrocarbylene group; 
         and M represents an alkali metal atom, to produce a copolymer, and 
         then reacting a compound containing at least one of a nitrogen atom and a silicon atom with an active terminal of the copolymer, 
         wherein the silicon-containing vinyl compound is a compound represented by the following formula (II): 
       
       
         
           
           
               
               
           
         
         wherein m represents 0; X 1 , X 2  and X 3  each represent a group represented by the following formula (IIa), or a hydrocarbyl group; at least one of X 1 , X 2  and X 3  is a group represented by the following formula (IIa), 
       
       
         
           
           
               
               
           
         
         wherein R 22  and R 23  each are an alkyl group, 
         wherein the compound containing at least one of a nitrogen atom and a silicon atom is at least one selected from the group consisting of 
         a compound represented by the following formula (IIIb), 
         a compound represented by the following formula (IIId), 
         a compound represented by the following formula (IV), a tris[(alkoxysilyl)alkyl] isocyanurate compound, and 
         an N,N-dialkyl-substituted carboxylic acid amide dialkyl acetal compound, 
       
       
         
           
           
               
               
           
         
         wherein R 32  represents a hydrocarbyl group; and R 36  represents a hydrocarbylene group, or a group in which a hydrocarbylene group and a group represented by —NR 35 — are bonded, where R 35  represents a hydrocarbyl group or a hydrogen atom, 
       
       
         
           
           
               
               
           
         
         where in R 31  and R 32  each represents a hydrocarbyl group; R 37  represents a hydrocarbylene group; A represents an oxygen atom or —NR 35 — wherein R 35  represents a hydrocarbyl group or a hydrogen atom; and R 34  represents a hydrocarbyl group or a hydrogen atom, 
       
       
         
           
           
               
               
           
         
         wherein R 41  represents a hydrocarbyl group; R 42  and R 43  each represent a hydrocarbyl group or a hydrocarbyloxy group; R 44  and R 45  each represents a hydro carbyl group; and j represents an integer of 1 to 5, 
         wherein an amount of the conjugated diene polymer is 25 to 75% by mass and an amount of a polyisoprene-based rubber is 0 to 40% by mass, each based on 100% by mass of the rubber component, and 
         an amount of the silica is 10 to 150 parts by mass for each 100 parts by mass of the rubber component. 
       
     
     
       2. The rubber composition according to  claim 1 ,
 wherein R 11  in the formula (I) is a group represented by the following formula (Ia): 
 
       
         
           
           
               
               
           
         
       
       wherein R 14  represents a hydrocarbylene group comprising at least one of a structural unit derived from a conjugated diene compound and a structural unit derived from an aromatic vinyl compound; and n represents an integer of 1 to 10. 
     
     
       3. The rubber composition according to  claim 2 ,
 wherein R 14  in the formula (Ia) is a hydrocarbylene group comprising from one to ten isoprene-derived structural unit(s). 
 
     
     
       4. The rubber composition according to  claim 1 ,
 wherein the conjugated diene polymer contains a structural unit derived from an aromatic vinyl compound. 
 
     
     
       5. The rubber composition according to  claim 1 ,
 wherein the silica includes silica (1) having a nitrogen adsorption specific surface area of at least 50 m 2 /g but less than 120 m 2 /g, and silica (2) having a nitrogen adsorption specific surface area of not less than 120 m 2 /g. 
 
     
     
       6. The rubber composition according to  claim 1 , comprising
 a solid resin having a glass transition temperature of 60 to 120° C. in an amount of 1 to 30 parts by mass for each 100 parts by mass of the rubber component. 
 
     
     
       7. The rubber composition according to  claim 1 ,
 wherein the silica includes silica (1) having a nitrogen adsorption specific surface area of at least 50 m 2 /g but less than 120 m 2 /g, and silica (2) having a nitrogen adsorption specific surface area of not less than 120 m 2 /g, and 
 the rubber composition comprises a solid resin having a glass transition temperature of 60 to 120° C. in an amount of 1 to 30 parts by mass for each 100 parts by mass of the rubber component. 
 
     
     
       8. The rubber composition according to  claim 1 , comprising
 a mercapto group-containing silane coupling agent in an amount of 0.5 to 20 parts by mass for each 100 parts by mass of the silica. 
 
     
     
       9. The rubber composition according to  claim 1 ,
 wherein the rubber composition comprises a mercapto group-containing silane coupling agent in an amount of 0.5 to 20 parts by mass for each 100 parts by mass of the silica, and 
 the silica includes silica (1) having a nitrogen adsorption specific surface area of at least 50 m 2 /g but less than 120 m 2 /g, and silica (2) having a nitrogen adsorption specific surface area of not less than 120 m 2 /g. 
 
     
     
       10. The rubber composition according to  claim 1 , comprising
 a mercapto group-containing silane coupling agent in an amount of 0.5 to 20 parts by mass for each 100 parts by mass of the silica, and 
 a solid resin having a glass transition temperature of 60 to 120° C. in an amount of 1 to 30 parts by mass for each 100 parts by mass of the rubber component. 
 
     
     
       11. The rubber composition according to  claim 1 ,
 wherein the rubber composition comprises a mercapto group-containing silane coupling agent in an amount of 0.5 to 20 parts by mass for each 100 parts by mass of the silica, 
 the silica includes silica (1) having a nitrogen adsorption specific surface area of at least 50 m 2 /g but less than 120 m 2 /g, and silica (2) having a nitrogen adsorption specific surface area of not less than 120 m 2 /g, and 
 the rubber composition comprises a solid resin having a glass transition temperature of 60 to 120° C. in an amount of 1 to 30 parts by mass for each 100 parts by mass of the rubber component. 
 
     
     
       12. The rubber composition according to  claim 1 ,
 wherein the rubber composition comprises a mercapto group-containing silane coupling agent in an amount of 0.5 to 20 parts by mass for each 100 parts by mass of the silica, and 
 the silane coupling agent is at least one of a compound represented by the formula (1) below, and a compound containing a linking unit A represented by the formula (2) below and a linking unit B represented by the formula (3) below, 
 
       
         
           
           
               
               
           
         
       
       wherein R 101  to R 103  each represent a branched or unbranched C 1-12  alkyl group, a branched or unbranched C 1-12  alkoxy group, or a group represented by —O—(R 111 —O) z —R 112  where z R 111 s each represent a branched or unbranched C 1 -30 divalent hydrocarbon group, and z R 111 s may be the same as or different from one another; R 112  represents a branched or unbranched C 1-30  alkyl group, a branched or unbranched C 2 -30 alkenyl group, a C 6 -30 aryl group, or a C 7 -30 aralkyl group; and z represents an integer of 1 to 30, and R 101  to R 103  may be the same as or different from one another; and R 104  represents a branched or unbranched C 1-6  alkylene group; 
       
         
           
           
               
               
           
         
       
       wherein R 201  represents a hydrogen atom, a halogen atom, a branched or unbranched C 1-30  alkyl group, a branched or unbranched C 2 -30 alkenyl group, a branched or unbranched C 2-30  alkynyl group, or the alkyl group in which a terminal hydrogen atom is replaced with a hydroxyl group or a carboxyl group; R 202  represents a branched or unbranched C 1-30  alkylene group, a branched or unbranched C 2 -30 alkenylene group, or a branched or unbranched C 2 -30 alkynylene group; and R 201  and R 202  may be joined together to form a cyclic structure. 
     
     
       13. The rubber composition according to  claim 1 ,
 wherein the silica includes silica (1) having a nitrogen adsorption specific surface area of at least 50 m 2 /g but less than 120 m 2 /g, and silica (2) having a nitrogen adsorption specific surface area of not less than 120 m 2 /g, and 
 the nitrogen adsorption specific surface areas and amounts of the silica (1) and the silica (2) satisfy the following inequalities:
   (Nitrogen adsorption specific surface area of silica (2))/(Nitrogen adsorption specific surface area of silica (1))≧1.4, and
 
   (Amount of silica (1))×0.06≦(Amount of silica (2))≦(Amount of silica (1))×15.
 
 
 
     
     
       14. The rubber composition according to  claim 1 , comprising at least one of
 at least one liquid resin having a glass transition temperature of −40 to 20° C. selected from the group consisting of aromatic petroleum resins, terpene resins, and rosin resins, and 
 a plasticizer having a glass transition temperature of −40 to 20° C., 
 wherein a combined amount of the liquid resin and the plasticizer is 1 to 30 parts by mass for each 100 parts by mass of the rubber component. 
 
     
     
       15. The rubber composition according to  claim 1 ,
 wherein the rubber composition has a tan δ peak temperature of not lower than −16° C. 
 
     
     
       16. A tread, formed from the rubber composition according to  claim 1 . 
     
     
       17. A pneumatic tire, formed from the rubber composition according to  claim 1 . 
     
     
       18. The pneumatic tire according to  claim 17 , wherein the wet grip performance index is equal to or between 106 and 125 and the handling stability is equal to or between 6 and 6.5.